Thermoelectric micro-module with high leg density for energy harvesting and cooling applications

ABSTRACT

Micro-scale thermoelectric devices having high thermal resistance and efficiency for use in cooling and energy harvesting applications and relating fabricating methods are disclosed. The thermoelectric devices include first substrates substantially parallel with second substrates. Scaffold members are deposited between the first and second substrate. The scaffold members include a plurality of cavities having sidewalls. The scaffold members may be formed from the second substrate. The sidewalls are substantially vertical with respect to the second substrate. The sidewalls may be substantially parallel. Thermoelectric materials are deposited on the sidewalls.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/280,274, filed on Jan. 19, 2016. The entire disclosure of the aboveapplication is incorporated herein by reference.

FIELD

The present disclosure relates to the field of micro-scale energyharvesting and refrigeration. In particular, the present disclosure is adesign and fabrication method for energy harvesters and coolersutilizing the thermoelectric effect.

BACKGROUND

The thermoelectric effect allows for the generation of an electricalpotential from a temperature difference that is generally proportionalto the temperature difference. The thermoelectric effect allowselectrical power to be directly generated from thermal energy.Conversely, the thermoelectric effect allows for the application ofelectrical power to move heat to generate a heat gradient. Therefore,the thermoelectric effect can be utilized to create both thermoelectricgenerators (“TEGs”) and thermoelectric coolers (“TECs”). Boththermoelectric devices generally consist of numerous pairs ofthermoelectric elements, commonly referred to as “legs,” combined into asingle module.

Small scale thermoelectric transducers are used for many commercialcooling applications, including central processing unit (“CPU”)heatsinks, laser diodes, and charged coupled detectors. There has been agrowing interest in using small TEGs to power wireless sensor networksfor applications, including structural health monitoring (“SHM”),environmental monitoring, and vehicle maintenance. A possible barrier tothe introduction of TEGs to these various applications is the relativelylow power generation and voltage output of TEGs.

In general, for maximum power generation, the ideal TEG requires: (1)high thermal resistance across its thermoelectric elements, (2) lowinternal electrical resistance, and (3) high voltage output per degree(K) of temperature difference across the device. For example, a highthermal resistance allows a large temperature gradient across thethermoelectric elements without the use of large heatsinks, which areoften impractical. Furthermore, because the generated voltage isproportional to the temperature difference across the thermoelectricelements, the larger thermal resistance increases power generation andefficiency. Generally, the thermal resistance for commercialmicro-fabricated TEGs ranges from 5 K/W to 20 K/W. In the instances ofTECs, thermal resistance and electrical resistance are similarlyimportant, however, there is only voltage input.

Characteristics of a TEG are primarily determined by the materialproperties of the thermoelectric materials comprising the legs and thestructural characteristics of the legs, including the active area of thelegs, the area density of the thermoelectric legs, and the length of thethermoelectric legs. The active area of the thermoelectric legs refersto the total cross sectional area of the legs perpendicular to the flowof the generated current. The total active area of all thethermoelectric legs over the device area is the fill factor. Generally,the ideal TEG structure includes: (1) long thermal electric legs forincreased thermal resistance, (2) a large active area for low electricalresistance, and (3) high leg density for large voltage output. High legdensity is especially important for low temperature applications becauseelectronics generally require a minimum voltage to operate.

The relative low performance of TEGs compared to theoretical limits is aresult of the difficulty of making thermoelectric legs having the idealstructural characteristics. For example, TEGs generally utilize highperformance thin film thermoelectric materials. However, it is generallydifficult to deposit the films with sufficient thickness to achieve ahigh thermal resistance in a vertical configuration. Moreover, lateralconfigurations, though capable of achieving high thermal resistances,are limited with respect to leg density and fill factor. Other methodshave been attempted, but have poor thermoelectric material performanceor high costs.

This section provides background information related to the presentdisclosure which is not necessarily prior art.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

According to an aspect of the present disclosure, a high-aspectthermoelectric device includes a first and second substrates comprisedof thermally conductive materials. The first and second substrates aresubstantially parallel and sandwich a scaffold member. The scaffoldmember has a first surface that faces the first substrate and a secondsurface that faces the second substrate. The first surface of thescaffold member includes a plurality of cavities. The cavities define aplurality of sidewalls formed at an angle less than fifteen degrees fromvertical and extending between the first and second substrates. Athermoelectric film comprised of thermoelectric materials is depositedonto the sidewalls of the cavities using a vapor deposition technique.

In certain instances, the thermoelectric materials are deposited ontothe sidewalls of the cavities using a physical vapor deposition process,such as evaporation, sputtering, or pulsed laser techniques.

In certain instances, the second substrate is formed of silicon (Si) andthe scaffold member is formed from the second substrate.

In certain instances, the high-aspect thermoelectric device alsoincludes a plurality of first contacts interposed between the firstsubstrate and the thermoelectric film. The first contacts mayselectively interconnect the individual thermoelectric materials to eachother.

In certain instances, the high-aspect thermoelectric device alsoincludes a plurality of second contacts interposed between the secondsubstrate and the thermoelectric film. The second contacts mayselectively interconnect the individual thermoelectric materials to eachother.

In certain instances, the high-aspect thermoelectric device alsoincludes contacts formed by overlapping adjacent thermoelectricelements.

In certain instances, the deposited thermoelectric materials may have asquare frustum shape.

In certain instances, the thermoelectric materials have a height between10 μm and 500 μm.

In certain instances, the thermoelectric materials are arranged in pairsto form thermoelectric legs. In such instances, each thermoelectric legpair includes a first leg member comprised of n-type thermoelectricmaterial and a second leg member comprised of p-type thermoelectricmaterial.

In certain instances, the thermoelectric film has a density ofthermoelectric legs ranging from 10 to 1000 thermoelectric leg pairs permm².

In certain instances, the n-type thermoelectric material is comprised ofbismuth telluride (Bi₂Te₃); bismuth selenide (Bi₂Se₃); gallium nitride(GaN); lead telluride (PbTe); cobalt antimonide (CoSb₃); lanthanumtelluride (LaTe); bismuth telluride selenide (Bi₂Te_((3-x))Se_(x),wherein x ranges from 0.1 to 1); or combinations thereof.

In certain instances, the p-type thermoelectric material is comprised ofantimony telluride (Sb₂Te₃); bismuth antimony telluride (Sb₃BiTe₆); leadtelluride (PbTe); lead tellurium selenide (Pb₂SeTe); silicon germanium(SiGe); (GeTe)_(x)(AgSbTe₂)_(y), wherein x ranges from 70 to 75 and yequals 100−x; and combinations thereof.

According to another aspect of the present disclosure, a high-aspectthermoelectric device including substantially parallel first and secondsubstrates comprised of thermally conductive material. The secondsubstrate includes a plurality of pillars that extend from a firstsurface of the second substrate. The pillars each define a firstsidewall and a second sidewall. The first sidewalls of the pillars facea first direction. The second sidewalls of the pillars face a seconddirection that opposes the first direction. The first sidewall and thesecond sidewall of each pillar are substantially parallel. The pillarsin the plurality of pillars are substantially parallel with each other.A thermoelectric film comprised of thermoelectric materials is depositedon the sidewalls of the pillars using a vapor deposition technique.

In certain aspects, the second substrate is comprised of silicon (Si).

In certain aspects, the thermoelectric materials include a firstthermoelectric material and a second thermoelectric material. The firstthermoelectric material is deposited on the first sidewalls of thepillars. The second thermoelectric material is deposited on the secondsidewalls of the pillars.

In certain aspects, the first thermoelectric material is a n-typethermoelectric material selected from the group consisting of: bismuthtelluride (Bi₂Te₃), bismuth selenide (Bi₂Se₃), gallium nitride (GaN),lead telluride (PbTe), cobalt antimonide (CoSb₃), lanthanum telluride(LaTe), bismuth telluride selenide (Bi₂Te_((3-x))Se_(x), wherein xranges from 0.1 to 1), and combinations thereof.

In certain aspects, the second thermoelectric material is a p-typethermoelectric material selected from the group consisting of: antimonytelluride (Sb₂Te₃), bismuth antimony telluride (Sb₃BiTe₆), leadtelluride (PbTe), lead tellurium selenide (Pb₂SeTe), silicon germanium(SiGe), (GeTe)_(x)(AgSbTe₂)_(y), wherein x ranges from 70 to 75 and yequals 100−x, and combinations thereof.

In certain aspects the first thermoelectric material is also depositedon first areas of the second substrate. The first areas of the secondsubstrate are immediately adjacent to the first sidewalls of thepillars.

In certain aspects the second thermoelectric material is also depositedon second areas of the second substrate. The second areas of the secondsubstrate are immediately adjacent to the second sidewalls of thepillars.

In certain aspects, the first areas and the second areas overlap to formthird areas of the second substrate. A composite of the first and secondthermoelectric materials is deposited on the third areas of the secondsubstrate.

According to another aspect of the present disclosure, a method offabricating a high-aspect thermoelectric device includes etching a firstsilicon substrate to form a plurality of pillars. The pillars extendfrom a first surface of the first substrate. Each pillar defines a firstsidewall and a second sidewall. The first sidewalls of the plurality ofpillars face a first direction. The second sidewalls of the plurality ofpillars face a second direction that opposes the first direction. Thefirst and second sidewalls of each pillar are substantially parallel,and pillars in the plurality of pillars are substantially parallel witheach other. The pillars are oxidized and a first thermoelectric materialis deposited on the first sidewalls of the pillars from a first source.A second thermoelectric material is deposited on the second sidewalls ofeach pillar from a second source. A second substrate is bonded onto thefirst substrate. The second and first substrates together sandwich thethermoelectric materials.

In certain instances, the method also includes depositing the firstthermoelectric material on a first area of the first substrate. Thefirst areas of the first substrate are immediately adjacent the firstsides of the oxidized pillars.

In certain instances, the method also includes depositing the secondthermoelectric material on a second area of the first substrate. Thesecond areas of the first substrate is immediately adjacent to thesecond side of each oxidized pillar

In certain instances, the first areas and the second areas overlap toform third areas of the first substrate. A thermoelectric compositionformed of the first and second thermoelectric material is deposited ontothe third areas of the first substrates.

In certain instances, the thermoelectric composites form electricalcontacts.

In certain instances, the first, second, and third areas of the firstsubstrate are defined by shadow makes deposited on exposed ends of eachpillar prior to the deposition of the first and second thermoelectricmaterials.

In certain instances, the first thermoelectric material is a n-typethermoelectric material comprised of bismuth telluride (Bi₂Te₃); bismuthselenide (Bi₂Se₃); gallium nitride (GaN); lead telluride (PbTe); cobaltantimonide (CoSb₃); lanthanum telluride (LaTe); bismuth tellurideselenide (Bi₂Te_((3-x))Se_(x), wherein x ranges from 0.1 to 1); orcombinations thereof.

In certain instances, the second thermoelectric material is a p-typethermoelectric material comprised of antimony telluride (Sb₂Te₃);bismuth antimony telluride (Sb₃BiTe₆); lead telluride (PbTe); leadtellurium selenide (Pb₂SeTe); silicon germanium (SiGe);(GeTe)_(x)(AgSbTe₂)_(y), wherein x ranges from 70 to 75 and y equals100−x; and combinations thereof.

In certain instances, each pillar has a height between 10 μm and 100 μm.

In certain instances, the pillars are separated from each other by adistance between 10 μm and 100 μm.

In certain instances, the first the first source is positioned at afirst angle relative to the first silicon substrate, and the secondsource is positioned at a second angle relative to the first siliconsubstrate.

In certain instances, the first source deposits the first thermoelectricmaterial and the second source deposited the second thermoelectricmaterial simultaneously.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1 is a cross-section of an exemplary thermoelectric device, whereinthe scaffold member is intact, cavities of the scaffold member havesidewalls that are substantially vertical with respect to the bottomsubstrate, and thermoelectric materials coat the sidewalls.

FIG. 2 is a cross-section of an exemplary thermoelectric device similarto that illustrated in FIG. 1, wherein the scaffold member has beenremoved.

FIG. 3 is a cross-section of an exemplary thermoelectric device similarto that illustrated in FIG. 2, wherein the thermoelectric materials formsolid thermoelectric blocks.

FIG. 4 is a prospective view of an exemplary thermoelectric device,wherein the scaffold member is intact.

FIG. 5 is a prospective view of an exemplary thermoelectric devicehaving a serial stacked configuration.

FIG. 6 is a prospective view of an exemplary thermoelectric devicehaving a parallel stacked configuration.

FIGS. 7A-7F illustrate an exemplary method for fabricating thethermoelectric device illustrated in FIG. 4. FIG. 7A illustrates asubstrate etched to form routing grooves. FIG. 7B illustrates depositionof routing metal into the grooves of the etch substrate. FIG. 7Cillustrates the bonding of a scaffold member to the bottom substrate.FIG. 7D illustrates the etching of the silicon substrate. FIG. 7Eillustrates deposition of thermoelectric materials onto the scaffoldmember (as further illustrated in FIGS. 8-10B). FIG. 7F illustratesdeposition of a top contact onto the deposited thermoelectric materials.

FIG. 8 illustrates a direct sputtering method for depositingthermoelectric materials onto the scaffold member.

FIGS. 9A-9B illustrates an angled evaporation method for depositingthermoelectric materials onto the scaffold member. FIG. 9A illustrates ascaffold member mounted at a first angle relative to a source. FIG. 9Billustrates the scaffold member mounted at a second angle relative tothe source.

FIGS. 10A-10B illustrates a hard press method for depositingthermoelectric materials onto the scaffold member. FIG. 10A illustratesthe deposition of powdered thermoelectric material within a cavity. FIG.10B illustrates the heating and pressing of the deposited thermoelectricmaterial to form a solid thermoelectric block.

FIG. 11 is a cross-section of another exemplary thermoelectric device,wherein the sidewalls are substantially parallel.

FIG. 12 is a cross-section of an exemplary thermoelectric device similarto that illustrated in FIG. 11, wherein the top substrate includes aplurality of pillars that interlock with the pillars of the bottomsubstrate and thermoelectric materials are deposited on the alternatingpillars of the top and bottom substrate.

FIG. 13 is a cross-section of an exemplary thermoelectric device similarto that illustrated in FIG. 11, wherein the scaffold is constructed fromthe bottom substrate.

FIG. 14 is a cross-section of an exemplary thermoelectric device similarto that illustrated in FIG. 13, wherein thermoelectric materials arealso deposited on the first surface of the bottom substrate.

FIGS. 15A-15E illustrates an exemplary method for fabricating thethermoelectric device illustrated in FIG. 14. FIG. 15A illustrates ablocked starting material. FIG. 15B illustrates the etched bottomsubstrate. FIG. 15C illustrates the oxidization of the pillars. FIG. 15Dillustrates the deposition of the first thermoelectric material ontopillars and the bottom substrate. FIG. 15E illustrates the deposition ofthe second thermoelectric material onto the pillars and the bottomsubstrate.

FIG. 16 illustrates an exemplary method for fabricating a thermoelectricdevice, wherein the method includes using shadow masks of various types.

FIG. 17 illustrates an exemplary method for fabricating a thermoelectricdevice, wherein the method includes simultaneously depositing of thefirst and second thermoelectric materials.

FIGS. 18A-18E provide another illustration of the exemplary method ofFIGS. 15A-15E. FIG. 18A illustrates the etched bottom substrate. FIG.18B illustrates the oxidation of the pillars and the first surface ofthe bottom substrate. FIG. 18C illustrates metal patterning of thebottom substrate. FIG. 18D illustrates deposition of the thermoelectricmaterials. FIG. 18E illustrates deposition of the top substrate.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference tothe accompanying drawings.

High-aspect, micro-scale vertical thermoelectric modules, or devices,having high thermal resistance and high efficiency are disclosed herein.Long thermoelectric materials are integrated into a thermoelectricdevice in a compact and area efficient manner. In general, thethermoelectric devices includes thermoelectric material deposited over ascaffold patterned by traditional microelectromechanical systems(“MEMS”) etching techniques. The deposited thermoelectric materialconforms to the shape of the scaffold and forms thermoelectric legpairs. MEMS based micromachining of the scaffold allows high densitypatterns to be formed and, subsequently, high thermoelectric legdensities. Additionally, the length of the thermoelectric legs and,thus, the thermal resistance, is uncoupled from the thickness of thethermoelectric film allowing for the creation of long, resistivethermoelectric legs with a vertical orientation. The presentthermoelectric devices are compatible with numerous thermoelectricmaterials. The thermoelectric devices may be used in cooling and energyharvesting applications.

FIG. 1 illustrates an exemplary thermoelectric device 10, wherein thescaffold member 12 is intact, cavities 42 of the scaffold member 12 havesidewalls 46 that are substantially vertical with respect to a bottomsubstrate 16, and thermoelectric materials 18, 20 coat the sidewalls 46of the cavities 42.

The thermoelectric device 10 includes a first substrate 14 (e.g., a topsubstrate) opposing a second substrate 16 (e.g., a bottom substrate).The top substrate 14 is substantially parallel with the bottom substrate16. The top substrate 14 has a first surface 28 that faces a firstsurface 30 of the bottom substrate 16. The top and bottom substrates 14,16 have a distance between them ranging from 10 μm to 500 μm. Forexample, the distance between the top and bottom substrates 14, 16 maybe between 20 μm and 200 μm. The top and bottom substrates 14, 16 mayhave a thickness of 500 μm.

The top and bottom substrates 14, 16 are comprised of thermallyconductive materials that have undergone passivation to preventelectrical shorting of the thermoelectric device 10. For example, thetop and bottom substrates 14, 16 comprise silicon (Si), aluminum (Al),nitride (N³⁻), silicon-germanium (SiGe), gallium arsenide (GaAs), orcombinations thereof. In certain instances, the top and bottomsubstrates 14, 16 may include flexible polyimide. The top and bottomsubstrates 14, 16 function as thermal terminals and packaging. The topsubstrate 14 may be a hot side, and the bottom substrate 16 a cold side.

A plurality of first contacts 22 (e.g., top contacts) are deposited onthe first surface 28 of the top substrate 14. A plurality of secondcontacts 24 (e.g., bottom contacts) are deposited on the first surface30 of the bottom substrate 16. The top and bottom contacts 22, 24 aresandwiched by the top and bottom substrates 14, 16. The top and bottomcontacts 22, 24 are electrical routings. For example, the top and bottomcontacts 22, 24 comprise solder; eutectic alloy; other metal capable ofthermocompression bonding, such as gold (Au), copper (Cu), or aluminum(Al); or combinations thereof.

A scaffold member (e.g., mold) 12 is deposited between the top andbottom substrates 14, 16. The scaffold member 12 is sandwiched by thetop and bottom substrates 14, 16. In certain instances, an adhesionlayer (not shown) may be deposited between the scaffold member 12 andthe bottom substrate 16. The adhesion layer may comprise chromium (Cr)or titanium (Ti) and have a thickness of less than or equal to 30 nm. Incertain instances, a polymer bonding layer (not shown) may be depositedbetween the scaffold member 12 and the top substrate 14.

The scaffold member 12 is comprised of thermally and electricallyisolating materials and mechanically supports the force of a bond fromthe top substrate 14. For example, the scaffold member 12 is comprisedof silicon (Si); fused silica or silicon oxide (SiO₂); SU-8; poly(methylmethacrylate) (“PMMA”); polyimide (“PI”); benzocyclobutene (“BCB:); orcombinations thereof. The scaffold member 12 has a thickness rangingfrom 10 μm to 500 μm. For example, the scaffold member 12 may have athickness between 20 μm and 200 μm.

The scaffold member 12 includes a plurality of cavities 42. The cavities42 each comprise four sidewalls 46, which together form the cavity 42.Cross-sections of two of the sidewalls 46 are shown FIG. 1. Eachsidewall 46 has a first and second end 32, 34. The first ends 32 facethe first surface 28 of the top substrate 14, and the second ends 34face the first surface 30 of the bottom substrate 16. The first andsecond ends 32, 34 make contact with the top and bottom contacts 22, 24,respectively.

The sidewalls 46 are substantially vertical with respect to the bottomsubstrate 16. For example, as seen in FIG. 1, the sidewalls may beformed at an angle less than fifteen degrees from vertical relative tothe bottom substrate 16. In other words, a first distance 36 separatesopposing sidewalls 46 at the first end 32, and a second distances 38separates opposing sidewalls 46 at the second end 34. For example, thefour sidewalls 46 together may form a cavity 42 having a square frustumshape. However, it is understood that the sidewalls 46 may form cavities42 having other shapes, including shapes wherein the first distance 36is larger than the second distance 38 and shapes wherein the firstdistance 36 equals the second distance 38.

The scaffold member 12 provides a vertical substrate upon which athermoelectric film, comprising n-type and p-type thermoelectricmaterials 18, 20, is deposited. In particular, the n-type and p-typethermoelectric materials 18, 20 rest on (i.e., coat) the sidewalls 46 ofthe cavities 42. Thus, the thermoelectric materials 18, 20 have a shapecorresponding to the sidewalls 46 the cavities 42. Therefore, forexample, the deposited thermoelectric materials 18, 20 may outline asquare frustum, (i.e., forms a hollow square frustum). As such, thepattering of the scaffold member 12 defines the length and density ofthe thermoelectric materials 18, 20. The thermoelectric materials 18, 20may have a height ranging from 10 μm to 500 μm. For example only, thethermoelectric materials 18, 20 may have a height between 20 μm and 200μm.

N-type and p-type thermoelectric materials 18, 20 are deposited inalternating cavities 42. As seen in FIG. 1, a n-type thermoelectricmaterial 18 is deposited in a first cavity 42 that is sandwiched bysecond and third cavities 42 in which p-type thermoelectric materials 20are deposited. The thermoelectric materials 18, 20 are arranged in pairsto form thermoelectric leg pairs 40. Each thermoelectric leg pair 40including a first leg member comprised of the n-type thermoelectricmaterial 18 and a second leg member comprised of the p-typethermoelectric material 20. The scaffold member 12 and thethermoelectric legs 40 together form a thermoelectric layer 48. Thethermoelectric legs 40 may have a length ranging from 10 μm to 500 μm.For example only, the thermoelectric legs 40 may have a length between20 μm and 150 μm.

The n-type thermoelectric material 18 is comprised of bismuth telluride(Bi₂Te₃); bismuth selenide (Bi₂Se₃); gallium nitride (GaN); leadtelluride (PbTe); cobalt antimonide (CoSb₃); lanthanum telluride (LaTe);bismuth telluride selenide (Bi₂Te_((3-x))Se_(x), wherein x ranges from0.1 to 1); or combinations thereof. The p-type thermoelectric material20 is comprised of antimony telluride (Sb₂Te₃); bismuth antimonytelluride (Sb₃BiTe₆); lead telluride (PbTe); lead tellurium selenide(Pb₂SeTe); silicon germanium (SiGe); (GeTe)_(x)(AgSbTe₂)_(y), wherein xranges from 70 to 75 and y equals 100−x; or combinations thereof.

The thermoelectric materials 18, 20 make contact with the top and bottomcontacts 22, 24. The top and bottom contacts 22, 24 connect thethermoelectric materials 18, 20 to one another, as well asthermoelectric leg pairs 40 to one another. Thus, each bottom contact 24makes contact with a first thermoelectric leg pair 40A, while each topcontact 22 makes contact with both first and second thermoelectric legpairs 40A, 40B. It is understood, however, that in other instances,among other arrangements, the top contacts may make contact with a firstthermoelectric leg pair, while the bottom contacts with both first andsecond thermoelectric leg pairs.

FIG. 2 illustrates an exemplary thermoelectric device 50 that is similarto thermoelectric device 10 of FIG. 1 except the scaffold member hasbeen removed. In certain instances, removal of the scaffold memberallows for increased thermal resistance. When the scaffold membercomprises silicon oxide, hydrogen fluoride (HF) wet or vapor etching maybe used to remove the scaffold member. Solvent etching or oxygen plasmaetching may be used to remove polymer scaffold members.

The thermoelectric device 50 comprises a top substrate 52 opposing abottom substrate 54; a plurality of top and bottom contacts 60, 62deposited on first surfaces 56, 58 of the top and bottom substrates 52,54, respectively; and a plurality of alternating n-type and p-typethermoelectric materials 64, 66 deposited therebetween, which togetherform thermoelectric leg pairs 68. Similar to FIG. 1, the depositedthermoelectric materials 64, 66 may each have a square frustum shape,which has a “v” or “u” shaped cross-section. As seen in FIG. 2, theclose-end of the “v” or “u” cross-section faces the first surface 58 ofthe bottom substrate 54 and makes contact with one of the bottomcontacts 62. While the open-end of the “v” or “u” cross-section facesthe first surface 56 of the top substrate 52 and makes contact with oneof the top contacts 60.

FIG. 3 illustrates an exemplary thermoelectric device 80 similar tothermoelectric device 50 of FIG. 2 except the thermoelectric materialsform solid thermoelectric blocks. In certain aspects, the thermoelectricdevice 80 may utilize in-plane properties. In other aspects, thethermoelectric device 80 may utilize out-of-plane properties. In otheraspects still, the thermoelectric device 80 may utilize both in-planeand out-of-plane properties. As discussed with respect to FIGS. 8-10Bbelow, the properties of the thermoelectric devices may be dependentupon the chosen deposition method.

The thermoelectric device 80 comprises a top substrate 82 opposing abottom substrate 84; a plurality of top and bottom contacts 90, 92deposited on first surfaces 86, 88 of the top and bottom substrates 82,84, respectively; and a plurality of alternating n-type and p-typethermoelectric materials 94, 96 deposited therebetween, which togetherform thermoelectric leg pairs 98. Similar to FIG. 2 the scaffoldingmember has been removed. Similar to FIGS. 1 and 2, the depositedthermoelectric materials 94, 96 may take a square frustum shape having afirst end 100 facing the first surface 88 of the bottom substrate 84 anda second end 102 facing the first surface 86 of the top substrate 82.However, unlike the thermoelectric materials of the previousembodiments, the thermoelectric materials 94, 96 of thermoelectricdevice 80 have a solid cross-section.

FIG. 4 provides a prospective view of an exemplary thermoelectric device120, wherein the scaffold member 126 is intact. Similar tothermoelectric device 10 of FIG. 1, the thermoelectric device 120 mayinclude thermoelectric materials 128, 130 that coat the sidewalls 152 ofrespective cavities 150. Alternatively, similar to thermoelectric device80 of FIG. 3, the thermoelectric device 120 may include thermoelectricmaterials 128, 130 that form solid thermoelectric blocks. Solidthermoelectric block materials have a higher fill factor and a lowerthermal resistance and will be used when the TEG system can rapidlyreject heat (e.g., large heatsink). Thermoelectric coatings are usedwhen limited by the heatsink. However, in certain aspects,thermoelectric coatings are used in a continuum and may be increaseduntil the coating resembles a solid block. The nature of thethermoelectric materials 128, 130 is visually indeterminable in thepresent prospective view.

Similar to the previous embodiments, the thermoelectric device 120comprises a bottom substrate 124; a plurality of bottom contacts 134disposed on a first surface 138 of the bottom substrate 124; a scaffoldmember 126; a plurality of thermoelectric materials 128, 130; and aplurality of top contacts 136 deposited on a top surface 144 of thethermoelectric materials 128. The scaffold member 126 is deposited onthe first surface 138 of the bottom substrate 124 and has plurality ofcavities 150. N-type and p-type thermoelectric materials 128, 130 arerespectively deposited within alternating cavities 150.

FIG. 5 illustrates an exemplary thermoelectric device 160 having aserial stacked configuration. The substrate and thermoelectric layersforming the serial stacked configuration of the present thermoelectricdevice 160 each have features comparable to those of the signal layerthermoelectric devices described above. However, in general,thermoelectric devices having multiple layers (i.e., a stackedconfiguration) produce greater temperature gradients when operated as acooler than thermoelectric devices having a single layer. The multiplelayers are each capable of maintaining a certain temperature drop beforejoule heating and heat conduction limits the cooling effect. Ifappropriately sized, the use of multiple layers increases thermalresistance and limits joule heating. The device is appropriately sizedif the first layer (i.e., the layer contacting the element to be cooled)has the smallest heat pump capacity and the second layer (i.e., thelayer adjacent to the first layer) has a larger heat pump capacity topump heat from the first stage and the additional heat from jouleheating. The last stage will have the greatest capacity because of theneed to pump the original heat plus additional heat from the jouleheating of the previous layers, or stages.

The thermoelectric device 160 includes top and bottom substrates 162,164 that are substantially parallel and that sandwich a plurality ofmiddle substrates 172 and thermoelectric layers 170. Each middlesubstrate has a first side 174 opposing a second side 176. The firstside 174 faces a first surface 166 of the top substrate 162, and thesecond side 176 faces a first surface 168 of the bottom substrate 164.First contacts 178 are deposited on the first surface 166 of the topsubstrate 162 and the second side 176 of each middle substrate 172.Second contacts 180 are deposited on the first surface 168 of the bottomsubstrate 164 and the first side 174 of each middle substrate 172.

Scaffold members 126 are sandwiched by the plurality of substrates 162,164, 172. A first scaffold member 126 is deposited between the topsubstrate 162 and a first middle substrate 172. A second scaffold member126 is deposited between the bottom substrate 164 and a final middlesubstrate 172. Other scaffold members 126 are deposited betweencorresponding middle substrate layers 172. As in the previousembodiments, each scaffold member 126 includes a plurality of cavities190 and n-type and p-type thermoelectric materials 184, 186 arerespectively deposited within alternate cavities 190. Similar tothermoelectric device 10 of FIG. 1, the present thermoelectric materials184, 186 of thermoelectric device 160 may coat the sidewalls 192 ofrespective cavities 190. Alternatively, similar to thermoelectric device80 of FIG. 3, thermoelectric device 160 may include thermoelectricmaterials 184, 186 that form solid thermoelectric blocks. Similar toFIG. 4, the nature of the thermoelectric materials 184, 186 is visuallyindeterminable in the present prospective view.

FIG. 6 illustrates an exemplary thermoelectric device 280 having aparallel stacked configuration. Similar to thermoelectric device 160 ofFIG. 5, thermoelectric device 280 includes a plurality of stackedsubstrate and thermoelectric layers. However, unlike thermoelectricdevice 160, thermoelectric device 280 also includes opposing left andright substrates that sandwich the stacked substrate and thermoelectriclayers. Parallel stacked configurations can increase the area of thethermoelectric material and thereby allow more energy to be harvested ina TEG and, comparatively, more heat to be pumped for a given device sizein a TEC.

The thermoelectric device 280 includes left and right substrates 282,284 that are substantially parallel and that sandwich a plurality ofmiddle substrates 292 and thermoelectric layers 290. The middlesubstrate layers 292 and the thermoelectric layers 209 are substantiallyparallel. The middle substrate layers are coupled to and extend from oneof the left or right substrates 282, 284. A first set first set ofmiddle substrates 292A are coupled to and extend from a first surface286 of the left substrate 282, while a second set of middle substrates292B are coupled to and extend from a first surface 288 of the rightsubstrate 284.

The middle substrates 292 and the thermoelectric layers 290 arecomparable to the top and bottom substrates and thermoelectric layers ofthe previously described devices. Each middle substrate 292 has a firstsurface 296 and an opposing second surface 298. A plurality of firstcontacts 300 is deposited on the second surface 298 of each middlesubstrate 292, except with respect to the bottom middle substrate 292. Aplurality of second contacts 302 is deposited on the first surface 296of each middle substrate 292, except with respect to the top middlesubstrate 292.

Scaffold members 304 are deposited between corresponding middlesubstrates 292. As in the previous embodiments, each scaffold member 304includes a plurality of cavities 310 and n-type and p-typethermoelectric materials 306, 308 are respectively deposited withinalternate cavities 310. Similar to thermoelectric device 10 of FIG. 1,thermoelectric materials 306, 308 of thermoelectric device 280 may coatthe sidewalls 312 of respective cavities 310. Alternatively, similar tothermoelectric device 80 of FIG. 3, thermoelectric device 280 mayinclude thermoelectric materials 306, 308 that form solid thermoelectricblocks. Similar to FIGS. 4 and 5, the nature of the thermoelectricmaterials 306, 308 is visually indeterminable in the present prospectiveview.

FIGS. 7A-7F illustrate an exemplary method for fabricating thethermoelectric device 120 illustrated in FIG. 4. It is understood,however, that similar methods may be used for fabrication of the otherthermoelectric devices described herein.

First, as illustrated in FIG. 7A, recesses 250 are etched into a bottomsubstrate 124. Second, as illustrated in FIG. 7B, routing metal isdeposited into the etched recesses 250 to from the bottom contacts 134(i.e., electrical connections). The routing metal 124 has a good contactresistant to the thermoelectric materials 128, 130. For example, therouting metal 134 comprises gold (Au); nickel (Ni); copper (Cu);eutectic metal combinations such as Au—Sn, Au—In, Sn—Ag—Cu, Pb—Sn; orcombinations thereof.

Third, as illustrated in FIG. 7C, the scaffold member 126 is depositedonto the first surface 138 of the bottom substrate 124. When thescaffold member comprises glass or fused silica, the scaffold member 126is vacuum bonded to the bottom substrate 124. When the scaffold membercomprises polyimide, the scaffold member 126 is directly deposited, orspun. Fourth, as illustrated in FIG. 7D, the scaffold member 126 isetched and cavities 150 formed. When the scaffold member 126 comprisesglass or fused silica, the scaffold member 126 is etched using reactiveion or wet etching. The scaffold member 126 is etched after selectiveexposure to light when the scaffold member comprises reactive polymersor dry etched (reactive ion etching (“RIE) or deep reaction ion etching(“DRIE”)) when comprised of phot-inert polymers.

Fifth, as illustrated in FIG. 7E, thermoelectric materials 128, 130 aredeposited within the cavities 150. In certain instances, as seen in FIG.1, the thermoelectric materials 128, 130 may be deposited alongsidewalls of the cavities 150. In other instances, as seen in FIG. 3,the thermoelectric materials 128, 130 are deposition within the cavities150 to form a solid thermoelectric blocks. FIGS. 8-10, described below,illustrate particular methods of depositing the thermoelectric materials128, 130. Generally, thin film deposition techniques are used. Forexample, physical vapor deposition (“PVD”) techniques, includingevaporation, sputtering, and pulsed laser may be used.

Once the thermoelectric materials 128, 130 are deposited, the scaffoldmember 126 connects the deposited thermoelectric legs 140 in a serialmanner. The high density patterning of the scaffold member 126 resultsin a high density of thermoelectric legs 140. For example, thethermoelectric device may have a density of ranging between 10 and 1000thermoelectric legs per mm². The connection in series of the highdensity thermoelectric legs 140 allow for the generation of largevoltages with small temperature gradients. Further, the scaffold member126 allows the length (seen as height in the present image) of thethermoelectric materials 128, 130 to be increased because the length isno longer limited by the thickness of the film. The length of thethermoelectric materials 128, 130 instead is dependent upon the depth ofthe scaffold member 126 and not the thickness of the thermoelectricmaterial 128, 130 deposited. As a result, thermal resistance isindependent of the film's thickness, which allows high thermalresistance to be achieved.

Sixth, as illustrated in FIG. 7F, top contacts 136 are deposited on thefirst ends 144 (e.g., top surface, exposed ends) of each thermoelectricmaterial 128, 130. Lastly, though not shown, a top substrate isdeposited opposing the bottom substrate 124. Similar to the bottomsubstrate 124 of FIGS. 7A and 7B, recesses may be etched and routingmetals deposited in the top substrate.

As referenced above, FIGS. 8-10 illustrate exemplary methods fordeposition of thermoelectric materials 128, 130 onto the scaffold member126. Material type, desired film thickness (fill factor), and ease ofmanufacturing are considered when selecting a deposition method.

FIG. 8 illustrates a direct sputtering method 198 for depositing thethermoelectric materials 128, 130 (collectively the thermoelectric film200) onto the scaffold member 126. In such instances, the thermoelectricmaterials 128, 130 are directly sputtered onto the sidewalls 152 using ahigh-pressure process. The deposited thermoelectric materials 128, 130may have a thickness of greater than 10 μm. The deposited thermoelectricmaterial 128, 130 has a combination of in-plane and out-of-planeproperties. The thermoelectric materials 128, 130 may be directlysputtered via magnetron to form the conformal thermoelectric coating(i.e., film) 200. In certain instances, multiple sputtering steps may beused to deposit the thermoelectric materials 128, 130. The multiplesputtering steps may allow for the formation of superlattices andquantum wells, which improve the performance of the thermoelectriccoating 200. Superlattices may increase the thermal resistivity byincreasing phonon scattering at the interfaces. Quantum wells mayenhance the Seebeck effect. The use of multiple sputtering steps mayalso reduce the stress held by the deposited thermoelectric coating(i.e., film) 200.

FIGS. 9A-9B illustrates an angled evaporation method for depositing thethermoelectric materials 128, 130 (collectively the thermoelectric film200) onto the scaffold member 126. The evaporation method may be used todeposit tellurium based thermoelectric materials. The thermoelectricmaterial 128, 130 deposited using the evaporation method may have amoderate thickness ranging between 2 μm and 10 μm.

During the evaporation process, the scaffold member 126 is alternatedbetween first and second angles 214, 216 relative to the source. Asseen, the scaffold member 126 may be angled relative to the source.However, in other instances, the source may be angled relative to thescaffold member 126. The repositioning of the scaffold member 126ensures consistent coating of all sidewalls 152 of the cavity 150. Forexample, if coating of all sidewalls 152 is desired, the scaffold member126 may be angle relative to the source and constantly rotated tocomplete a full 360 degree turn. In other instances, the scaffold member126 may be rotated in increments of 90 degree to coat each desired wall.The properties of the thermoelectric film 200 depend upon the particularangle of deposition. In certain aspects, the smaller the angle of thesource relative to the scaffold member 126 the closer the properties ofthe thermoelectric film 200 will be to out-of-plane.

FIG. 9A illustrates the scaffold member 126 mounted at a first angle 214relative to a source. In such instances, the thermoelectric material128, 130 is thermally evaporated onto the first sidewall 152A. FIG. 9Billustrates the scaffold member 126 mounted at a second angle 216relative to the source. In such instances, the thermoelectric material128, 130 is thermally evaporated onto the second sidewall 152B. The flowof thermoelectric material 128, 130 in each instance is illustrated byarrows 224.

FIGS. 10A-10B illustrates a hard press (i.e., sintering) method fordepositing thermoelectric materials 128, 130 (collectively thethermoelectric film 200) onto the scaffold member 126. Generally, thethermoelectric materials 128, 130 are pressed into alternate cavities150 to form solid bodies. First, as illustrated in FIG. 10A, powderthermoelectric materials 200 are placed within respective cavities 150.The powder thermoelectric materials 128, 130 are deposited until therespective cavities 150 are filled to full capacity. Second, asillustrated by FIG. 10B, heat and pressure 236 is applied in an inertenvironment comprising argon (Ar) or nitrogen (N) and a pressure plate242 presses and sinters the powered thermoelectric material 128, 130into a solid thermoelectric block 202. For example, the thermoelectricmaterials 200 may be heated to 450° C. and a pressure greater than 2.5GPa applied. Arrows 244 represent the direction of force applied by thepressure plate 242. In certain aspects, the thermoelectric film 200formed using a hard press method may have out-of-plane properties.

FIG. 11 illustrates an exemplary thermoelectric device 470 similar tothe thermoelectric devices described above except the sidewalls of thecavities are substantially parallel. Similar to the previousembodiments, the thermoelectric device 470 comprises a top substrate 472opposing a bottom substrate 474; a plurality of top and bottom contacts476, 478 deposited on first surfaces 480, 482 of the top and bottomsubstrates 472, 474, respectively; a scaffold member 490 sandwiched bythe top and bottom substrates 472, 474; and a plurality of alternatingn-type and p-type thermoelectric materials 486, 488 deposited onto thescaffold member 490.

The scaffold member 490 forms a plurality of pillars 494 and valleys(i.e., cavities) 492 therebetween. In certain instances, the pillars 494may be rectangular. The pillars 494 may have a height ranging from 10 μmto 500 μm. For example, the pillars 494 may have a height between 20 μmand 200 μm. The pillars 494 may have a thickness of 2 μm. The pillars494 include a first sidewall 496 opposing a second sidewall 498. Thefirst sidewalls 496 of the pillars 494 face a first direction. Thesecond sidewalls 498 of the pillars 494 face a second direction thatdirectly opposes the first direction. The first and second sidewalls496, 498 are substantially parallel. The pillars 494 forming theplurality are substantially parallel with each other. For example, afirst pillar 494 of the plurality may be substantially parallel with asecond pillar 494 of the plurality. Further, the second pillar 494 maysubstantially parallel with a third pillar 494.

Similarly to the previous embodiments, the sidewalls 496, 498 aresubstantially vertical with respect to the bottom substrate 472. Forexample only, the sidewalls 496, 498 may be substantially ninety-degreesvertical with respect to the bottom substrate 472. The sidewalls 496,498 of the pillar 494 may be perpendicular with respect to the bottomsubstrate 472. The thermoelectric materials 486, 488 are deposited onopposing sidewalls 496, 498. The n-type thermoelectric material 486 isdeposited on the first sidewall 496 of each pillar. The p-typethermoelectric material 488 is deposited on the second sidewall 498 ofeach pillar. As such, the scaffold member 490 provides a near verticalsubstrate upon which thermoelectric materials 486, 488 are deposited.

Bottom contacts 478 align with the valleys 492. A composition of then-type and p-type thermoelectric materials 486, 488 forms a connectingthermoelectric film 484 that is deposited on top of the bottom contacts478 and a top surface 506 of each pillar 494. The connectingthermoelectric films 484 may have a thickness of 5 μm. Top contacts 476align with the connecting thermoelectric film 484 deposited on the topsurfaces 506 of the pillars 494 and serves as bonding layer for the topsubstrate 472. The connecting thermoelectric film 484 and the top andbottom contacts 476, 478 form parallel electrical path links between then-type and p-type thermoelectric materials 486, 488. The top and bottomcontacts 476, 478 also reduce the resistance of the connection betweenthermoelectric legs.

It is recognized that in certain instances, the top substrate may have asimilar pillar structure as the bottom substrate. In such instances,pillars extending from the top substrate may interlock with pillarsextending from the bottom substrate. FIG. 12 illustrates an exemplarythermoelectric device 508 similar to thermoelectric device 470illustrate in FIG. 11 except the top substrate includes a plurality ofpillars that interlock with the pillars of the bottom substrate and then-type and p-type thermoelectric materials are deposited on thealternating pillars of the top and bottom substrate.

The thermoelectric device 508 comprises a top substrate 510 opposing abottom substrate 512. A plurality of top pillars 518 are deposited on afirst surface 514 of the top substrate 510. A plurality of bottompillars 520 are deposited on a first surface 516 of the bottom substrate512. The top pillars 518 interlock with the bottom pillars 520 formingan interlocking pattern. N-type thermoelectric materials 522 coat thetop pillars 518. P-type thermoelectric material 524 coats the bottompillars 520. Top contacts 532 are deposited on the first surface 514 ofthe top substrate 510 and align with a distal end 526 of the top pillars518. Bottom contacts 530 are deposited on the first surface 516 of thebottom substrate 512 and align with a distal end 528 of the bottompillars 520.

FIG. 13 illustrates an exemplary thermoelectric device 320 similar tothermoelectric device 470 illustrated in FIG. 11 except the pillars areformed from a bottom substrate comprised of silicon (Si) and acomposition of the n-type and p-type thermoelectric materials serves asthe top and bottom contacts.

The thermoelectric device 320 comprises a top substrate 322 opposing abottom substrate 324 formed of silicon (Si). A first surface 328 of thebottom substrate 324 is etched to form a scaffold including a pluralityof pillars 332. Similar to FIG. 11, the pillars 332 include a firstsidewall 338 opposing a second sidewall 340. The sidewalls 338, 340 aresubstantially parallel and ninety-degrees vertical with respect to thetop and bottom substrates 322, 324. The pillars 332, and consequentiallythe first surface 328 of the bottom substrate 324, are oxidized usingwet oxidation in a furnace. The pillars 332 are oxidized substantiallythroughout. The pillars may be fully oxidized so that no elementalsilicon remains.

N-type and p-type thermoelectric materials 334, 336 are respectivelydeposited on the oxidized sidewalls 338, 340. A composite of the n-typeand p-type thermoelectric materials 486, 488 forms a connectingthermoelectric film 346. The connecting thermoelectric film 370 isdeposited on the top surfaces 354 of the oxidized pillars 332 and on theoxidized first surface 328 of the bottom substrate 324 between thepillars 332. The connecting thermoelectric films 370 electricallyconnect the thermoelectric members 334, 336 to one another and thethermoelectric leg pairs to one another. The connecting thermoelectricfilms 370 may be supplemented with later deposited metal.

FIG. 14 illustrates an exemplary thermoelectric device 360 similar tothermoelectric device 320 illustrated in FIG. 13 except thermoelectricmaterials are also deposited on the first surface of the bottomsubstrate. Thermoelectric device 360 comprises a top substrate 376opposing a bottom substrate 378 and a plurality of oxidized pillars 364extending from a first surface 382 of the bottom substrate 378 andhaving opposing first and second sidewalls 384, 386.

Thermoelectric materials 366, 368 are deposited on the sidewalls 384,386 of each pillar 364 and on the first surface 382 of the bottomsubstrate 378. The first surface 382 of the bottom substrate 378 issegmented into portions. The bottom substrate 378 includes a firstportion 392 adjacent to the first side of each pillar 364; a secondportion 394 adjacent to the second side of each pillar 364; and a thirdportion 396 therebetween. N-type thermoelectric material 366 isdeposited on the first sidewall 384 of each pillar 364 and on the firstportions 392 of the bottom substrate 378. P-type thermoelectric material368 is deposited on the second sidewall 386 of each pillar 364 and onthe second portions 394 of the bottom substrate 378. A composite 370 ofthe n-type and p-type thermoelectric materials 366, 368 is deposited onthe third portion 396 of the bottom substrate 378 and on the topsurfaces 374 of the oxidized pillars 332.

Physical separation of the n-type and p-type thermoelectric materials366, 368 results from a shadowing effect of the pillars 364 (describedbelow). The first sidewalls 384 upon which the n-type thermoelectricmaterial 366 is deposited are the first members of respectivethermoelectric leg pairs, and the second sidewalls 386 upon which thep-type thermoelectric material 368 is deposited are the second membersof respective thermoelectric leg pairs. The first and second members(i.e., the first and second legs of the leg pair) are connected by thecomposite 370 of the n-type and p-type thermoelectric materials 366,368.

FIGS. 15A-15E illustrates an exemplary method for fabricating thethermoelectric device 360 illustrated in FIG. 14. It is understood,however, that similar methods may be used for fabrication of the otherthermoelectric devices described above.

FIG. 15A depicts the starting bottom substrate 378. First, asillustrated in FIG. 15B, the bottom substrate 378 is etched, orpatterned to form the scaffolding, including the plurality pillars 364extending from the first surface 382 of the bottom substrate 378. Thebottom substrate 378 may be patterned using dry etching. Second, asillustrated in FIG. 15C, the pillars 364 are oxidized. As a result theoxidation of the pillars 364, the first surface 382 of the bottomsubstrate 378 is also oxidized.

Third, as illustrated in FIG. 15D, a second source 428 deposits thep-type thermoelectric material 368 onto the second sidewalls 386. Thesecond source 428 also deposits the p-type thermoelectric materials 368onto the second and third portions 394, 396 of the bottom substrate 378.The second source 428 may be positioned at an angle between 30 and 60degrees relative to the second sidewalls 386. Shadows 430 are casted bythe pillars 364 relative to the second source 428. The shadows 430define the deposition area and causes p-type thermoelectric material 368not to be deposited onto the first sidewalls 384 or corresponding firstportions 392. The area of deposition for the p-type thermoelectricmaterial 368 is illustrated by cone 434.

Fourth, as illustrated in FIG. 15E, a first source 436 deposits then-type thermoelectric material 366 onto the first sidewall 384 of eachpillar 364. The first source 436 also deposits the n-type thermoelectricmaterials 366 onto the first and third portions 392, 396 of the bottomsubstrate 378. The first source 436 may be positioned at an anglebetween 30 and 60 degrees relative to the first sidewalls 384. Shadows438 are casted by the pillars 364 relative to the first source 436. Theshadows 438 define the deposition area and causes n-type thermoelectricmaterial 366 not to be deposited onto the second sidewalls 386 orcorresponding second portions 394. The area of deposition for the firstthermoelectric material 366 is illustrated by cone 440.

Both the first source 436 and second source 428 deposits thethermoelectric materials 366, 368 in an anisotropic fashion byline-of-sight thermal evaporation. Both thermoelectric materials 366,368 are deposited on the third portion 396 of the bottom substrate 378.Thus, the third portion 396 of the bottom substrate 378 is defined bythe overlap of deposition cones 434 and 440. The composite of the twothermoelectric materials 366, 368 forms the connecting thermoelectricfilm 370. As seen in FIG. 16, other shadow masks 442 of various sizesand shapes may be used in either instance (deposition of the first orsecond thermoelectric material 366, 368) to alter the shadow 446 castedand the corresponding deposition cones 448.

In certain instances, as seen in FIGS. 15A-15 E, the thermoelectricmaterials 366, 368 are deposited at separate times. In other instances,as seen in FIG. 17, the thermoelectric materials 366, 368 are depositedsimultaneously. Simultaneous deposition of the thermoelectric materials366, 368 is possible because of the shadowing effect of the pillars 364and the resulting physically separate of the first and secondthermoelectric materials 366, 368.

FIGS. 18A-18E provide another illustration of the exemplary method ofFIGS. 15A-15E. First, as illustrated in FIG. 18A, the bottom substrate378 is etched. Second, as illustrated in FIG. 18B, the pillars 364 areoxidized. The first surface 382 of the bottom substrate 378 is alsooxidized, but as a result of the oxidation of the pillars 364. Third, asillustrated in FIG. 18C, metal patterning 462 of the bottom substrate378 occurs. The deposited metal 462 may form electrical terminals andconnect columns 540. Separating the thermoelectric films into themultiple columns 540 increases the leg density and the output voltage,which is needed for low temperature application. Fourth, as illustratedin FIG. 18D, the thermoelectric materials 366, 368 are deposited.Lastly, as illustrated in FIG. 18E, the top substrate 376 is deposited.

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor layer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

1. A high-aspect thermoelectric device, comprising: a first substratecomprised of thermally conductive material; a second substrate comprisedof thermally conductive material and substantially parallel with thefirst substrate; a scaffold member having a first surface and a secondsurface sandwiched between the first substrate and the second substrate,wherein the first surface of the scaffold member faces the firstsubstrate and the second surface of the scaffold member faces the secondsubstrate, the first surface of the scaffold member includes a pluralityof cavities, and each cavity defining a plurality of sidewalls formed atan angle less than fifteen degrees from vertical and extending betweenthe first substrate and the second substrate; and a thermoelectric filmcomprised of thermoelectric materials and deposited on the sidewalls ofthe cavities using a vapor deposition technique.
 2. The high-aspectthermoelectric device of claim 1, wherein the thermoelectric film isdeposited on the sidewalls of the cavities using a physical vapordeposition process, wherein physical vapor deposition processes includeevaporation, sputtering, and pulsed laser techniques.
 3. The high-aspectthermoelectric device of claim 1, wherein the second substrate iscomprised of silicon (Si) and the scaffold member is formed from thesecond substrate.
 4. The high-aspect thermoelectric device of claim 1,further comprising: a plurality of first contacts interposed between thefirst substrate and the thermoelectric film and selectivelyinterconnecting individual thermoelectric materials to each other; and aplurality of second contacts interposed between the second substrate andthe thermoelectric film and selectively interconnecting individualthermoelectric materials to each other.
 5. The high-aspectthermoelectric device of claim 1, further comprising: contacts formed byoverlapping adjacent thermoelectric materials.
 6. The high-aspectthermoelectric device of claim 1, wherein the deposited thermoelectricmaterials have a square frustum shape.
 7. The high-aspect thermoelectricdevice of claim 1, wherein thermoelectric materials have a heightranging from 10 μm to 500 μm.
 8. The high-aspect thermoelectric deviceof claim 1, wherein the thermoelectric materials are arranged in pairsto form thermoelectric legs, each thermoelectric leg pair including afirst leg member comprised of n-type thermoelectric material and asecond leg member comprised of p-type thermoelectric material.
 9. Thehigh-aspect thermoelectric device of claim 8, wherein the thermoelectricfilm has a density of thermoelectric legs ranging from 10 to 1000thermoelectric legs per mm².
 10. The high-aspect thermoelectric deviceof claim 8, wherein the thermoelectric legs of have a length rangingfrom 10 μm to 500 μm.
 11. The high-aspect thermoelectric device of claim8, wherein the n-type thermoelectric material is selected from the groupconsisting of: bismuth telluride (Bi₂Te₃); bismuth selenide (Bi₂Se₃);gallium nitride (GaN); lead telluride (PbTe); cobalt antimonide (CoSb₃);lanthanum telluride (LaTe); bismuth telluride selenide(Bi₂Te_((3-x))Se_(x), wherein x ranges from 0.1 to 1); and combinationsthereof.
 12. The high-aspect thermoelectric device of claim 8, whereinthe p-type thermoelectric material is selected from the group consistingof: antimony telluride (Sb₂Te₃); bismuth antimony telluride (Sb₃BiTe₆);lead telluride (PbTe); lead tellurium selenide (Pb₂SeTe); silicongermanium (SiGe); (GeTe)_(x)(AgSbTe₂)_(y), wherein x ranges from 70 to75 and y equals 100−x; and combinations thereof.
 13. A high-aspectthermoelectric device, comprising: a first substrate comprised ofthermally conductive material; a second substrate comprised of thermallyconductive material and substantially parallel with the first substrate,wherein the second substrate includes a plurality of pillars extendingfrom a first surface of the second substrate towards the firstsubstrate, each pillar defines a first sidewall and a second sidewall,the first sidewalls of the pillars face a first direction, the secondsidewalls of the pillars face a second direction opposing the firstdirection, the first sidewall and the second sidewall of each pillar aresubstantially parallel, and pillars in the plurality of pillars aresubstantially parallel with each other; and a thermoelectric filmcomprised of thermoelectric materials and deposited on the sidewalls ofthe pillars using a vapor deposition technique.
 14. The high-aspectthermoelectric device of claim 13, wherein the second substrate iscomprised of silicon (Si).
 15. The high-aspect thermoelectric device ofclaim 13, wherein a first thermoelectric material is deposited on thefirst sidewalls of the pillars, and a second thermoelectric material isdeposited on the second sidewalls of the pillars.
 16. The high-aspectthermoelectric device of claim 15, wherein the first thermoelectricmaterial is a n-type thermoelectric material selected from the groupconsisting of: bismuth telluride (Bi₂Te₃), bismuth selenide (Bi₂Se₃),gallium nitride (GaN), lead telluride (PbTe), cobalt antimonide (CoSb₃),lanthanum telluride (LaTe), bismuth telluride selenide(Bi₂Te_((3-x))Se_(x), wherein x ranges from 0.1 to 1), and combinationsthereof; and the second thermoelectric material is a p-typethermoelectric material selected from the group consisting of: antimonytelluride (Sb₂Te₃), bismuth antimony telluride (Sb₃BiTe₆), leadtelluride (PbTe), lead tellurium selenide (Pb₂SeTe), silicon germanium(SiGe), (GeTe)_(x)(AgSbTe₂)_(y), wherein x ranges from 70 to 75 and yequals 100−x, and combinations thereof.
 17. The high-aspectthermoelectric device of claim 15, wherein the first thermoelectricmaterial is deposited on first areas of the second substrate, whereinthe first areas are immediately adjacent to the first sidewalls of thepillars; and the second thermoelectric material is deposited on secondareas of the second substrate, wherein the second areas are immediatelyadjacent to the second sidewalls of the pillars.
 18. The high-aspectthermoelectric device of claim 17, wherein the first areas and thesecond areas overlap to form third areas of the second substrate whereona thermoelectric composite of the first and second thermoelectricmaterials is deposited.
 19. A method of fabricating a high-aspectthermoelectric device, the method comprising: etching a first siliconsubstrate to form a plurality of pillars extending upwardly from a firstsurface of the first substrate, each pillar defining a first sidewalland a second sidewall, wherein the first sidewalls of the pillars face afirst direction, the second sidewalls of the pillars face a seconddirection opposing the first direction, the first sidewall and thesecond sidewall of each pillar are substantially parallel, and pillarsin the plurality of pillars are substantially parallel with each other;oxidizing the pillars; depositing a first thermoelectric material ontothe first sidewall of each oxidized pillar from a first source;depositing a second thermoelectric material onto the second sidewall ofeach oxidized pillar from a second source; and bonding a secondsubstrate onto the first substrate and thereby sandwiching thethermoelectric material between the first substrate and the secondsubstrate, wherein a first surface of the second substrate faces thefirst surface of the first substrate.
 20. The method of claim 19,further comprising: depositing the first thermoelectric material onfirst areas of the first substrate, wherein the first areas areimmediately adjacent to the first sidewalls of the oxidized pillars; anddepositing the second thermoelectric material on second areas of thesecond substrate, wherein the second areas are immediately adjacent tothe second sidewalls of the oxidized pillars.
 21. The method of claim20, wherein the first areas and the second areas overlap to form thirdareas of the first substrate whereon a thermoelectric composite of thefirst and second thermoelectric materials is deposited.
 22. The methodof claim 21, wherein the thermoelectric composite forms electricalcontacts.
 23. The method of claim 21, wherein the first, second, andthird areas of the first substrate are defined by shadow masks depositedon exposed ends of each pillar prior to deposition of the first andsecond thermoelectric materials. 24.-29. (canceled)